THE COPPER TUBE HANDBOOK

www.copper.org

bleeding.indd 1bleeding.indd 1 8/3/2010 5:12:18 PM8/3/2010 5:12:18 PM

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Structural adhesive joining ofcopper and copper alloy tube is fast,economical and, most importantly,requires no heat or open flame as isrequired for soldering or brazing.

Structural adhesive joiningutilizes a complete system consisting ofa specially designed fitting thatincorporates a lip-seal type elastomericgasket and a specially formulated two-part epoxy structural adhesive.

Although the engineered fittingsand adhesive are patented andspecifically required to be usedtogether, any copper tube meeting therequirements of ASTM B88 in types K,L or M, drawn (hard temper) orannealed (soft temper), can be used.Typical ranges of pressure-temperatureratings for these no-flame joints arefound in Table 4b, page 29. (Tube sizesand specific limitations must meetmanufacturers' recommendations.)

Preliminary RequirementsExamine the tube to ensure it

reveals no dents, deep scratches, dirt,oils, paint, grease or other surfaceimperfections.

Fittings must be examined toinsure they are structural adhesive typefittings, the lip-seal gasket is in placeand in good condition, and the fittingdoes not show evidence of dirt orconstruction debris inside.

Remove burrs from the I.D. and theO.D. of the tube end by reaming theI.D. and chamfering the O.D using theappropriate tools.

Chamfer the cut tube end to reducethe possibility of gasket damage wheninserting the tube. Cleaning of thechamfered tube end with emery paper,nylon abrasive cloth or plumbers clothwill insure that no sharp edges or nicksare present which could damage thesealing capacity of the gasket uponinsertion of the tube into the fitting.

XIII. STRUCTURAL ADHESIVE JOINTS

Installation Steps Measure accurately to insure the tubewill socket to the back of the fitting cup.

Cut the tube square, perpendicular tothe run of the tube, using an appropriatetube cutter.

FIGURE 74: Check tube for imperfections

FIGURE 78: Reaming tools

FIGURE 79: Chamfer tool

XIII. STRUCTURAL ADHESIVES

FIGURE 75: Structural adhesive fitting

FIGURE 76: Measuring

FIGURE 77: Cutting the tube squareFIGURE 80: Chamfering the tube end

Clean the tube end by wiping it withalcohol to remove any residual surfaceoils, dirt or construction debris prior toapplying the adhesive. This will ensureproper bonding of the structuraladhesive.

Mark the depth of insertion plus on the tube so that full insertion can beensured when assembling the tube tofitting.

Apply a small bead of adhesive to thetube end O.D. close to the cut end. Insizes 1 and greater, an additionalapplication of a small bead of adhesivemust be applied to the inside of thefitting before the lip-seal gasket. Thebead applied to the inside of the fittingmust be less than the height of the lip-seal gasket for best results. (There areseveral forms of fittings for thestructural adhesive system, such asthose that require application ofadhesive directly through holes in thecup of the fitting, and application of theadhesive should be in accordance withthe manufacturers' instructions.)

Insert the tube into the fitting. Propertube insertion can be ensured if thefitting is from the insertion depthmark. (It should be noted that, in somefabrications, there are times whenapplying a mark from the face of thefitting would be almost impossiblebecause of the ability to actually buttfittings up against each other. In suchcase, another means of ensuing propertube-to-fitting insertion should be used.)

Following assembly and finaladjustment of fitting orientation, theadhesive should be visible around theentire circumference of the fitting-to-tube interface. Care should be exercisedto ensure the joint is permitted to cureas required, based on the work-life/set-time for the adhesive being utilized.

TestingTesting of the completed piping

system should be undertaken only afterthe appropriate length of cure time haselapsed from the fabrication of the lastjoint in the system.

Final pressure testing of thecompleted piping system can beaccomplished by using pressurized airor water as required by local codes orproject specifications. (Note: testpressures should never exceed themaximum operating pressure specifiedby the manufacturer of the fittingsystem.)

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FIGURE 87: Inserting tube end

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FIGURE 83: Use alcohol to clean tube end

FIGURE 81: Cleaning the tube end

FIGURE 82: Prepared tube end

FIGURE 84: Wipe with premoistenedalcohol wipe or pad

FIGURE 85: Marking insertion depth

FIGURE 86: Applying adhesive to tube end

FIGURE 88: Ensuring proper insertion depth

FIGURE 89: Visual check of adhesive coverage

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Another joining technology thathas been used effectively for manyyears involves a hand tool designed toquickly pull tee connections and outletsfrom the run of the tube, thus reducingthe number of tee fittings and solderedor brazed joints. It allows branches tobe formed faster and usually results in alower installed system cost. Thismethod may be used for generalplumbing, HVAC, refrigeration, firesprinkler and service projects.

Portable hand tool kits and poweroperated equipment are available thatproduce lap joints for brazing. Thesystem can be used with Types K, L orM copper tube to form to 4 outletsfrom to 8 tubes, depending on toolselection. The installation descriptionsbelow are for illustrative purposes only.It is essential that the manufacturersinstructions and guidelines are followedexactly to ensure proper installation andsafe performance.

Preliminary Requirements Be sure to have all tool kit

components handy. They typicallyinclude:

is quickly repeatable. Follow themanufacturers operating instructionsfor all tube sizes.

Select and adjust the drill head andforming pins according to themanufacturers instructions. The drillbit and pins are quite sharp, so cautionis in order.

Insert the drill head into the chuckand extend the forming pins.

Lubricate the drill head and formingpins.

Press in the conical cover and rotatecounterclockwise to retract the formingpins.

XIV. MECHANICALLY FORMED EXTRUDED OUTLETS

The tee-forming power drill or handoperated outlet pulling tools and themanufacturers instructions for their useand proper application.

A tube end prep tool that forms theend of a branch pipe to match the innercurve of the run tube whilesimultaneously pressing two dimples inthe end of the branch tube. One acts as adepth stop and the other for inspectionof the joint after brazing.

Be sure the pipes (run and branch) aredrained and not under pressure.

Installation Steps The procedure that follows is

typical for the forming and brazing of to 1 outlets using power operatedequipment. Although there are specificsteps to be followed, the tee-formingand brazing process takes little time and

XIV. MECHANICALLY FORM

ED EXTRUDED OUTLETS

FIGURE 90: Mechanically formedextruded outlet requires only one brazed joint FIGURE 91: Power operated accessory

tool kit

FIGURE 92: Hand operated accessory tool kit

FIGURE 93 (a and b): Chucking the drillhead assembly

a

b

On tube sizes over 2, the area forforming the tee outlet must be annealedfirst. See manufacturers instructionswhen dealing with these sizes.

Pull out the support legs and place thetube support firmly onto the pointwhere the tee is to be formed on the

tube. Then, twist the machinecounterclockwise at the handle of thetool to center the drill head on the tube.The legs will center and support thedrill while absorbing all rotationaltorque.

Start the tool by squeezing the triggerand drill until the bit has fullypenetrated into the tube. Then, releasethe trigger to stop the drill.

Extend the forming pins on the drillhead by pressing the cover toward thetool and rotating it counterclockwiseuntil the head locks in the tee-formingposition. Do not extend the forming pinswhile the motor is running.

Turn the speed selector control to theslowest position (typical). Engage thefeed mechanism. You may have torotate the motor by giving a nudge onthe trigger.

Squeeze the trigger to startforming the outlet and continue until thedrill head is completely out of the tube.Maintain a slight downward pressure onthe drill to ensure a firm contact withthe tube. The rotation of the formingpins causes a back flow and thickeningof the metal around the lowercircumference of the outlet.

It is important to release the drilltrigger as soon as the drill head clearsthe rim of the outlet. NOTE: Removingthe drill head from the tube before itemerges will result in an oval orimperfect outlet.

Ream or deburr the branch tube end.

Choose the appropriate branch-sizedye on the tube-end notcher to notchand dimple the sides of the branch tubeend. Proper notching and dimpling mustbe performed to meet code require-ments and to ensure the branch does notprotrude into the tube.

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FIGURE 96: Positioning the drill tip andensuring a snug fit of the support legs

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FIGURE 94 (a and b): Lubricating the drill head

FIGURE 95 (a and b): Retracting the forming pins

FIGURE 97 (a and b): Extending theforming pins inside the run tube

FIGURE 98: Forming the outlet

FIGURE 99: Reaming the branch tube end

a

b

a

b a

b

Remove any excess lubricant frominside the outlet and use Scotchbriteor sand cloth to clean the inside of theoutlet rim.

Insert the branch tube into the outletup to the first dimple and align thedimples with the run of the tube.

Braze the joint.

TestingAll drilling residue and debris

must be flushed out before using thesystem.

Final pressure testing of thecompleted piping system isaccomplished by using pressurized airor water as required by local codes orproject specifications. (Note: testpressures should never exceed themaximum operating pressure specifiedby the manufacturer of the fittingsystem.)

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XIV. MECHANICALLY FORM

ED EXTRUDED OUTLETS

FIGURE 103: Aligning the dimples withthe run of the tube

FIGURE 100: Using the notching anddimpling tool

FIGURE 101: Properly prepared branchend tube

FIGURE 102: Ensuring the inside rimsurface is clean

FIGURE 104: Finished joint

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AFSA - American Fire SprinklerAssociation

12750 Merit Drive, Suite 350Dallas, TX 75251(214) 349-5965 www.firesprinkler.org

AGA - American Gas Association400 North Capitol Street, NWWashington, DC 20001(202) 824-7000 www.aga.org

AHRI - Air-Conditioning, Heating andRefrigeration Institute

2111 Wilson Blvd., Suite 500Arlington, VA 22201(703) 524-8800 www.ahrinet.org

ANSI - American NationalStandards Institute

1819 L Street, NWWashington, DC 20036(202) 293-8020 www.ansi.org

APFA - American Pipe FittingsAssociation, Inc.

201 Park Washington Court Falls Church, VA 22046(703) 538-1786 www.apfa.com

ASHRAE - American Society ofHeating, Refrigeration & Air-Conditioning Engineers, Inc.

1791 Tullie Circle, NEAtlanta, GA 30329-2305(404) 636-8400 www.ashrae.org

ASME - American Society ofMechanical Engineers

3 Park AvenueNew York, NY 10016-5990(212) 591-7000 www.asme.org(800) 843-2763

ASPE - American Society of PlumbingEngineers

2980 S. River Rd. Des Plaines, IL 60018 (847) 296-0002 www.aspe.org

ASNT - American Society for Non-destructive Testing

P.O. Box 285181711 Arlingate Lane Columbus, OH 43228-0518(800) 222-2768 www.asnt.org

ASSE - American Society of SanitaryEngineering

901 Canteberry, Suite AWestlake, OH 44145(440) 835-3040www.asse-plumbing.org

ASTM International100 Barr Harbor Drive, P.O. Box C700West Conshohocken, PA 19428-2959(610) 832-9500 www.astm.org

AWS - American Welding Society550 NW LeJeune RoadMiami, FL 33126-0440(305) 443-9353 www.aws.org

AWWA - American Water WorksAssociation

6666 W. Quincy AvenueDenver, CO 80235(303) 794-7711 www.awwa.org

CDA - Copper DevelopementAssociation Inc.

260 Madison Avenue (16th Fl)New York, NY 10016(212) 251-7200 www.copper.org

CGA- Compressed Gas Association, Inc.4221 Walney Road, 5th FlChantilly, VA 20151-2923(703) 788-2700 www.cganet.com

CIPH - Canadian Institute of Plumbingand Heating

295 The West Mall, Suite 330Toronto, Ontario, M9C 4Z4(416) 695-0447 www.ciph.com

CCBDA - Canadia Copper and BrassDevelopment Association

49 The Donway West, Suite 415 North York, Ontario, M3C 3M9(416) 391-5591www.coppercanada.ca

GAMA - Gas Appliance ManufacturersAssociation (See AHRI)

IAPMO - International Association ofPlumbing and Mechanical Officials

5001 E. Philadelphia St. Ontario, CA 91761 (909) 472-4100 www.iapmo.org

ICC - International Code Council500 New Jersey Avenue, NW, 6th Fl Washington, DC 20001(888) 422-7233 www.iccsafe.org

MCAA - Mechanical ContractorsAssociation of America

1385 Picard DriveRockville, MD 20850-4340(301) 869-5800 www.mcaa.org

NACE - National Association ofCorrosion Engineers

1440 South Creek DriveHouston, TX 77084-4906(281) 228-6200 www.nace.org

APPENDIX ORGANIZATIONS

XV. A

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DIX

NFPA - National Fire ProtectionAssociation

One Batterymarch ParkQuincy, MA 02169-7471(800) 344-3555 www.nfpa.org

NFSA - National Fire SprinklerAssociation

40 John Barrett RoadPatterson, NY 12563(845) 878-4200 www.nfsa.org

NSF InternationalP.O. Box 130140789 N. Dixboro RoadAnn Arbor, MI 48113-0140(734) 769-8010 www.nsf.org

SMACNA - Sheet Metal and AirConditioning Contractors NationalAssociation

4201 Lafayette Center DriveChantilly, VA 20151-1209(703) 803-2980 www.smacna.org

UA - United Association of Journeymenand Apprentices of the Plumbingand Pipefitting Industry of theUnited States and Canada

Three Park PlaceAnnapolis, MD 21401(410) 269-2000 www.ua.org

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XV. APPENDIX